MECHATRONICS

ELECTRONIC CONTROL SYSTEMS

IN MECHANICAL AND ELECTRICAL
ENGINEERING

Sixth Edition

William Bolton

PEARSON

Harlow, England •London New York

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Contents

Preface xi
3. Signal conditioning 69

Chapter objectives 69
I. Introduction 1
3.1 Signal conditioning 69

3.2 The operational amplifier 70

1. Introducing mechatronlcs 3 3.3 Protection 81

3.4 Filtering 83

3.5 Wheatstone bridge 84

Chapter objectives 3
3.6 Pulse modulation 88
1.1 What is mechatronics? 3
3.7 Problems with signals 89
1.2 The design 5
process
3.8 Power transfer 92
1.3 Systems 6
Summary 92
1.4 Measurement systems 8
Problems 93
1.5 Control systems 9

1.6 Programmable logic controller 21

1.7 Examples of mechatronic systems 22

Summary 25 4. Digital signals 95

Problems 26

Chapter objectives 95

4.1 Digital signals 95

II. Sensors and signal conditioning 27 4.2 Analogue and digital signals 95
4.3 Digital-to-analogue and analogue-to-digital
converters 99
2. Sensors and transducers 29
4.4 Multiplexers 105

4.5 Data acquisition 106

Chapter objectives 29 4.6 Digital signal processing 109
2.1 Sensors and transducers 29 Summary 110
2.2 Performance terminology 30 Problems 110

2.3 Displacement, position and proximity 35

2.4 Velocity and motion 46

2.5 Force 49
5. Digital logic 112
2.6 Fluid pressure 50
2.7 Liquid flow 54
2.8 Liquid level 55 Chapter objectives 112
2.9 Temperature 56 5.1 Digital logic 112

2.10 61 5.2 Logic 113

Light sensors gates
2.11 Selection of sensors 62 5.3 Applications of logic gates 120
2.12 Inputting data by switches 63 5.4 Sequential logic 126
65 Summary 133
Summary
Problems 66 Problems 133
 vi CONTENTS

6. Data presentation systems 136 9. Electrical actuation systems 207

Chapter objectives 136 Chapter objectives 207

6.1 Displays 136 9.1 Electrical systems 207
6.2 Data presentation elements 137 9.2 Mechanical switches 207

6.3 Magnetic recording 142 9.3 Solid-state switches 209

6.4 Optical recording 146 9.4 Solenoids 215
6.5 Displays 147 9.5 Direct current motors 217
6.6 Data acquisition systems 151 9.6 Alternating current motors 225
6.7 Measurement systems 155 9.7 Stepper motors 227
6.8 Testing and calibration 158 9.8 Motor selection 234
Summary 160 Summary 237
Problems 160 Problems 237

III. Actuation 163 IV. Microprocessor systems 239

7. Pneumatic and hydraulic actuation 10. Microprocessors and microcontrollers 241

systems •

165

Chapter objectives 241

Chapter objectives 165 10.1 Control 241
7.1 Actuation systems 165 10.2 Microprocessor systems 241
7.2 Pneumatic and hydraulic systems 165 10.3 Microcontrollers 253
7.3 Directional control valves 169 10.4 Applications 272
7.4 Pressure control valves 173 10.5 Programming 274
7.5 Cylinders 175 Summary 277
7.6 Servo and proportional control Problems 277
valves 178
7.7 Process control valves 180
7.8 Rotary actuators 185
11. Assembly language 278
Summary 186
Problems 186
Chapter objective 278
11.1 Languages 278
11.2 Instruction sets 279
8. Mechanical actuation systems 188 11.3 Assembly language programs 285
11.4 Subroutines 290
11.5 Look-up tables 293
Chapter objectives 188
11.6 Embedded systems 296
8.1 Mechanical systems 188
8.2 of motion Summary 300
Types 189
8.3
Problems 300
Kinematic chains 191
8.4 Cams 194
8.5 Gears 196
8.6 Ratchet and 12. C language 302
pawl 200
8.7 Belt and chain drives 200
8.8 Bearings 202
Chapter objectives 302
Summary 204 12.1 WhyC? 302
Problems 205 12.2 Program structure 302
 CONTENTS vil

12.3 Branches and loops 309 15.3 Networks 379

12.4 Arrays 313 15.4 Protocols 381

12.5 Pointers 315 15.5 Open Systems Interconnection

12.6 Program development 316 communication model 382
12.7 Examples of programs 317 15.6 Serial communication interfaces 385
12.8 Arduino programs 320 15.7 Parallel communication interfaces 391

Summary 323 15.8 Wireless protocols 394

Problems 324 Summary 395

Problems 395

13. Input/output systems 326

16. Fault finding 397

Chapter objectives 326

Chapter objectives 397
13.1 Interfacing 326
16.1 Fault-detection techniques 397
13.2 Input/output addressing 326
16.2 Watchdog timer 398
13.3 Interface requirements 329

interface adapters 336

16.3 Parity and error coding checks 399
13.4 Peripheral
16.4 Common hardware faults 400
13.5 Serial communications interface 341
16.5 Microprocessor systems 402
13.6 Examples of interfacing 344
16.6 Emulation and simulation 405
Summary 347
16.7 PLC systems 407
Problems 348
Summary 409
Problems 410

14. Programmable logic controllers 349

V. System models 411

Chapter objectives 349

14.1 Programmable logic controller 349 17. Basic system models 413
14.2 Basic PLC structure 349
14.3 Input/output processing 353
Chapter objectives 413
14.4 Ladder programming 354

358
17.1 Mathematical models 413
14.5 Instruction lists
17.2 Mechanical system building blocks 414
14.6 Latching and internal relays 361
17.3 Electrical system building blocks 422
14.7 Sequencing 363
364
17.4 Fluid system building blocks 426
14.8 Timers and counters
17.5 Thermal system building blocks 433
14.9 Shift registers 367
Summary 436
14.10 Master and jump controls 368
Problems 437
14.11 Data handling 369

14.12 Analogue input/output 371

373
Summary i
Problems 374 18. System models

Chapter objectives 439

376 18.1 Engineering systems 439

15. Communication systems
18.2 Rotational-translational systems 439

18.3 Electro-mechanical systems 440

376
Chapter objectives 18.4 Linearity 443
15.1 Digital communications 376 445
18.5 Hydraulic-mechanical systems
15.2 Centralised, hierarchical and distributed 448
Summary
control 376 448
Problems
vili CONTENTS

22.4 Proportional mode 510

19. Dynamic responses of systems 449 22.5 Derivative control 512
22.6 Integral control 514
22.7 PID controller 516
Chapter objectives 449
22.8 Digital controllers 517
19.1 Modelling dynamic systems 449
450 22.9 Control system performance 520
19.2 Terminology
452 22.10 Controller tuning 521
19.3 First-order systems
22.11 Velocity control 523
19.4 Second-order systems 458
19.5 Performance measures for second-order
22.12 Adaptive control 523

Summary 526
systems 464

19.6 identification 467 Problems 527

System
Summary 467
Problems 469

23. Artificial Intelligence 528

20. System transfer functions 471 Chapter objectives 528

23.1 What is meant by artificial intelligence? 528

23.2 Perception and cognition 528
Chapter objectives 471
23.3 Reasoning 530
20.1 The transfer function 471
23.4 Learning 533
20.2 First-order systems 474
Summary 534
20.3 Second-order systems 476
Problems 534
20.4 Systems in series 478

20.5 Systems with feedback loops 479

20.6 Effect of pole location on transient response 480

Summary 484 VI. Conclusion 535

Problems 484

24. Mechatronlc systems 537

21. Frequency response 486

Chapter objectives 537

24.1 Mechatronic designs 537

Chapter objectives 486 24.2 Case studies 548

21.1 Sinusoidal input 486 24.3 Robotics 563
21.2 Phasors 487 Summary 567
21.3 Frequency response 489 Problems 567

21.4 Bode plots 492 Research assignments 568

21.5 Performance specifications 501 Design assignments 568
21.6 Stability 502
Summary 503
Problems 504
Appendices 569

A The Laplace transform 571

22. Closed-loop controllers 505

A.l The Laplace transform 571

Chapter objectives 505 A.2 Unit steps and impulses 572
22.1 Continuous and discrete control processes 505 A.3 Standard Laplace transforms 574
22.2 Terminology 507 A.4 The inverse transform 578
22.3 Two-step mode 509 Problems 580
 CONTENTS ix

B Number systems 581 E C library functions 601

B.l Number systems 581

B.2 Binary mathematics 582
B.3 Floating numbers 585
F MATLAB and SIMULINK 604
B. 4 Gray code 585

Problems 586
F.l MATLAB 604

F. 2 SIMULINK 608

C Boolean algebra 587

G Electrical circuit analysis 610

C. l Laws of Boolean algebra 587

C.2 De Morgan's laws 588

C.3 Boolean function generation from truth tables 589 G. l Direct current circuits 610
C.4 Karnaugh maps 591 G.2 Alternating current circuits 615

Problems 594

Further information 620

Answers 624
D Instruction sets 596
Index 639